Method of Fabricating an Integrated Device

ABSTRACT

A method of fabricating an integrated device including a MicroElectroMechanical system (MEMS) and an associated microcircuit is provided. In one embodiment, the method comprises: forming a high temperature capable contact through a dielectric layer to an underlying element of a microcircuit formed adjacent to a MicroElectroMechanical System (MEMS) structure on a substrate; and depositing a layer of conducting material over the dielectric layer, and patterning the layer of conducting material to form a local interconnect (LI) for the microcircuit overlying and electrically coupled to the contact and a bottom electrode for the adjacent MEMS structure. Other embodiments are also provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of priority under 35 U.S.C.119(e) to U.S. Provisional Patent Application Ser. No. 61/201,887,entitled “CMOS Fabrication Flow for MEMS Adjacent Interconnect,” filedDec. 16, 2008, which application is hereby incorporated by reference inits entirety.

TECHNICAL FIELD

The present invention relates to integrated devices, and moreparticularly to methods of integrating a MicroElectroMechanical System(MEMS) and associated microcircuits on the same chip.

BACKGROUND

Combining MicroElectroMechanical System (MEMS) and associatedmicrocircuits or ICs (integrated circuits), such as drivers, onto acommon substrate would produce significant advantages including, forexample, higher channel counts. Unfortunately, the manufacturingprocesses for ICs and the MEMS devices are generally not compatible, andthus the direct integration of MEMS and microcircuit onto a monolithicsubstrate is challenging. Particularly challenging is integratingcontact and metallization technology commonly used in microcircuitfabrication with high temperature processes of MEMS fabrication withoutcompromising contact performance.

The current technology utilizes deep contacts formed after fabricationof the MEMS is substantially or entirely complete. This approach worksbut limits the minimum contact feature size due to the aspect ratio ofthe contacts. Conversely, a height or vertical stack-up of the MEMS islimited by the contact capability.

SUMMARY

A method of monolithically fabricating an integrated device including aMicroElectroMechanical systems (MEMS) device and an associatedmicrocircuit or integrated circuit on a single substrate is provided.Generally, the method comprises: forming a high temperature capablecontact through a dielectric layer to an underlying element of amicrocircuit formed adjacent to a MicroElectroMechanical System (MEMS)structure on a substrate; and depositing a layer of conducting materialover the dielectric layer, and patterning the layer of conductingmaterial to form a local interconnect (LI) for the microcircuitoverlying and electrically coupled to the contact and a bottom electrodefor the adjacent MEMS structure. Preferably, the method further includesdeposition and patterning of alternating dielectric and metal layers toform at least two metal interconnect layers (M1 and M2) in themicrocircuit, while the MEMS structure is protected from the dry etchprocesses used to pattern the metal layers by a first interleveldielectric layer (ILD). More preferably, after completion of theinterconnect layers (M1 and M2), remaining dielectric material isremoved from the MEMS structure using a highly selective buffered oxide(BOE) wet etch process. Other embodiments are also provided.

BRIEF DESCRIPTION OF THE DRAWINGS

These and various other features of the invention will be apparent uponreading of the following detailed description in conjunction with theaccompanying drawings and the appended claims provided below, where:

FIG. 1 is a perspective view of a ribbon-type spatial light modulator(SLM) for which a method according to an embodiment of the presentdisclosure is particularly useful;

FIG. 2 is a perspective view of a planar light valve type SLM for whicha method according to an embodiment of the present disclosure isparticularly useful;

FIG. 3 is a cross-sectional view of a MEMS formed adjacent to amicrocircuit having a 3-level metallization scheme according to anembodiment of the present disclosure;

FIG. 4 is a cross-sectional view of a MEMS formed adjacent to amicrocircuit having a 3-level metallization scheme and ahigh-temperature contact according to an embodiment of the presentdisclosure;

FIGS. 5A-5H are cross-sectional views through a substrate illustratingan embodiment of a fabrication process of an integrated device accordingto the present disclosure; and

FIGS. 6A and 6B is a flowchart illustrating a method of fabricating anintegrated device according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

The present disclosure is directed generally to an integrated deviceincluding a MicroElectroMechanical System (MEMS) formed adjacent to amicrocircuit, and methods of forming or fabricating the same. The methodis particularly useful for fabricating a MEMs spatial light modulator(SLM), such as a Grating Light Valve (GLV™) or a Planar Light Valve(PLV™), both of which are commercially available from Silicon LightMachines, Inc., of Sunnyvale, Calif., and its associated driver.

Referring to FIG. 1, a ribbon-type SLM 100 generally includes a numberof ribbons 102 a, 102 b; each having a light reflective surface 104supported over a surface 106 of a substrate 108. One or more of theribbons 102 a are deflectable toward the substrate 108 to form anaddressable diffraction grating with adjustable diffraction strength.The ribbons are 102 a deflected towards base electrodes (not shown inthis figure) formed in or on the substrate 108 by electrostatic forceswhen a voltage is applied between the deflectable ribbons 102 a and thebase electrodes. The applied voltages controlled by drive electronics(not shown in this figure), which may be integrally formed in or on thesurface 106 of the substrate 108 below or adjacent to the ribbons 102.Light reflected from the movable ribbons 102 a adds as vectors ofmagnitude and phase with that reflected from stationary ribbons 102 b ora reflective portion of the surface 106 beneath the ribbons, therebymodulating light reflected from the SLM 100.

Ribbon-type spatial light modulators 100 are increasingly being used innumerous applications including, for example, display systems, opticalinformation processing and data storage, printing, and masklesslithography. However, for many applications requiring high or very highresolution, such as maskless lithography in leading edge semiconductorand MEMS fabrication, SLMs having a two-dimensional array of MEMS arepreferred.

Referring to FIG. 2, one such type of SLM, the PLV™ 200 generallyincludes two films or membranes having light reflecting surfaces ofsubstantially equal area and reflectivity disposed above an uppersurface of a substrate (not shown in this figure). The topmost membraneis a static tent member or faceplate 202 of a uniform, planar sheet of amaterial having a first planar light reflective surface, for example ataut silicon-nitride film having an aluminized surface. The faceplate202 covers an underlying actuator membrane 210, which includes a numberof flat, displaceable or movable pistons or actuators 204. An array ofapertures 206 extend through the faceplate 202 to expose in theunderlying actuators 204. The actuators 204 have second planar lightreflective surfaces parallel to the light reflective surface of thefaceplate 202 and positioned relative to the apertures 206 to receivelight passing through the apertures. Each of the actuators 204, theassociated apertures 206 and a portion of the faceplate 202 immediatelyadjacent to and enclosing the aperture form a single, individual PLVcell, diffractor cell or diffractor 208.

Individual actuators 204 or groups of actuators are moved up or downover a very small distance (typically only a fraction of a wavelength ofincident light) relative to the first planar light reflective byelectrostatic forces controlled by drive electrodes in the substrateunderlying the actuator membrane. Preferably, the actuators 204 can bedisplaced by n*λ/4 wavelength, where λ. is a particular wavelength oflight incident on the first and second planar light reflective surfaces,and n is an integer equal to or greater than 0. Moving the actuators 204brings reflected light from the second planar light reflective surfaceinto constructive or destructive interference with light reflected bythe first planar light reflective surface, thereby modulating lightincident on the PLV™ 200.

As noted above, the size and position of each of the apertures 206 aregenerally predetermined to satisfy an “equal reflectivity” constraint.That is the reflectivity of the area of a single actuator 204 inside acell or diffractor 208 is equal to the reflectivity of the remainingarea of the diffractor that is outside the aperture 206. If thereflectivity of each of the first and second surfaces are the same, thenthis principle reduces to an “equal area” constraint. As an example ofthe “equal area” constraint, where the faceplate 202 contains an arrayof circular apertures 206 in square-shaped diffractors 208, as shown inFIG. 2, the area of a circular aperture 206 inside in a unit lengthsquare diffractor 208 is equal to the remaining area (outside circle butinside square).

The faceplate 202 is generally static or stationary and may be anchoredor secured to the substrate, for example, by a number of posts regularlyspaced across the PLV™ 200, or only at a perimeter of the PLV™. In apreferred embodiment, the faceplate 202 is periodically secured to theunderlying substrate by posts at each corner of each pixel or diffractor208. More preferably, the faceplate 202 includes an electricallyconductive material, such as titanium-nitride (TiN), and is electricallycoupled to a ground in the substrate through one or more of the posts.Alternatively, the faceplate 202 could be electrically floating toeliminate possible deformation under electrostatic force frominteraction with actuator drive electrodes in the substrate.

FIG. 2 also shows a cut away view of a portion of the actuator membrane210 including a single 3×3 pixel 212. In the embodiment shown, theactuator 204 of the diffractor 208 includes uniform, planar disks 218each having a planar reflective surface and flexibly coupled by hingesor flexures 220 of an elastic material, such as silicon-nitride(Si_(x)N_(y)), to one or more posts 216.

Integrated devices including a MEMS and a microcircuit monolithicallyformed on a single substrate or chip according to embodiments of thepresent invention and methods of fabricating the same will now bedescribed with reference to FIG. 3-6. For purposes of clarity, many ofthe details of MEMS and IC fabrication, which are widely known and notrelevant to the present invention, have been omitted from the followingdescription. MEMS and IC fabrication methods are described, for example,in commonly assigned U.S. Pat. No. 6,767,751, entitled, “Integrateddriver process flow,” by James Hunter, issued on Jul. 27, 2004.

A cross-sectional side view of a portion of an integrated device 300including a MEMS 302 and a microcircuit 304 monolithically formed in andon a single substrate 306 is shown in FIG. 3. Referring to FIG. 3, themicrocircuit 304 generally includes a plurality of transistors 308separated by isolation structures, such as field oxidation (FOX 310) andincluding doped source-drain regions 312 and gates 314 formed in thesubstrate 306 adjacent to and/or underlying the MEMS 302. Contacts 316extend through openings etched in a dielectric layer 318 covering thetransistors 308 to electrically couple gates 314 of the transistors andother regions in the substrate 306 to a local interconnect (LI 320) forthe wiring of the microcircuit 304. Additional alternating metal anddielectric layers are formed over the LI 320 to electrically couplethereto. It has been found that reasonably sophisticated circuitdesigns, such as those used to operate or drive a MEMS 302, can berealized with a microcircuit 304 including a total of three to fivemetal layers including the LI. In the embodiment shown, the microcircuit304 includes a first patterned metal layer (M1 322) overlying a firstinter-level dielectric layer (ILD 324) and patterned to form contactselectrically coupled to the LI 320, and a second patterned metal layer(M2 326) overlying a second ILD 328 electrically coupled to the metallayer. Optionally, each layer of metallization, i.e., LI 320, M1 322 andM2 326, and the entire microcircuit 304 are covered by cap-oxides (notshown).

The MEMS 302 generally includes at least one moveable actuator 330, aportion of which is suspended above the substrate 306 and separatedtherefrom by a gap 332 or void formed by the removal of a sacrificiallayer (not shown) following formation of the actuator. Where the MEMS302 is a diffractive, spatial light modulator (SLM), the actuator 330generally includes a layer of elastic material, such as silicon nitridelayer 334, covered or overlaid by a film or layer of metal 336 thatserves as both an actuator electrode and a reflective surface for theSLM. In operation the actuator 330 is electrostatically deflected ormoved towards a bottom electrode 338 formed in or on a surface of thesubstrate 306 by application of a voltage differential applied betweenthe electrode and the layer of metal 336 of the actuator.

As noted above, one problem with manufacture of integrated devices 300using conventional fabrication techniques is that the metallization usedto form the interconnects and contacts of the microcircuit 304 cannotwithstand the high temperature processes used to fabricate the MEMS 302.Thus, the MEMS 302 must be fabricated first, after the forming of thetransistors 308, prior to the metallization to form the microcircuit304, and material overlying the MEMS removed in an open array etch step.This has a number of negative impacts on fabrication of the integrateddevice 300. First, the MEMS is overlaid with a number of alternatingmetal and dielectric layers that must be removed after completion of themicrocircuit. Second, no contacts 316, and therefore few or notransistors, can be formed under the MEMS, thereby increasing thesurface area of the device dedicated to the microcircuit 304 andcorrespondingly decreasing the area of the MEMS and the opticalefficiency. Finally, the conventional approach typically results in highaspect ratio contacts 316, which are problematic from a standpoint ofyield of working devices, and can limit the number of layers ofmetallization in the microcircuit, since it is undesirable to have toomany layers overlying the MEMS that must be removed, and the MEMS issusceptible to damage through over etching used in the metallizationprocesses.

Accordingly, in a first aspect of the present invention a method offabricating an integrated device is provided in which all cap-oxides areeliminated and thicknesses of metallization and dielectric layers LI320, M1 322, M2 326, dielectric layer 318, ILD 324 and ILD 328, arereduced using process controls and chemical mechanical planarization(CMP). In particular, referring to FIG. 3, it has been found limitingthe overall height (h) of the metallization and dielectric layers to 3.7microns (μm) and more preferably to 2.8 or less, problems with openingor exposing the MEMS 302 and with aspect ratios of the contacts 316 aresubstantially avoided. This is accomplished by following eachmetallization and dielectric deposition with a CMP process to limit eachLI and metal layer to thicknesses of from about 500 to about 5000Angstroms (Å), and each dielectric layer and ILD to thicknesses of fromabout 2000 to about 6000 (Å). Although not shown, the LI and metallayers can further include waffling, that is adding a dummy features orwaffles in regions where a pattern density of the metal lines is low toimprove CMP.

It will be appreciated that an advantage of the above approach is thatit can be readily included in existing fabrication process flows,substantially without the introduction of new materials or steps, andenables the realization of more complex microcircuits having three ormore levels of metallization.

In another aspect, an integrated device and method of forming the sameare provided that utilizes high temperature capable contacts. By a hightemperature capable contact it is meant a contact capable ofwithstanding the higher processing temperatures of subsequent MEMSfabrication steps. Because the high temperature capable contacts areformed before MEMS fabrication, it is possible to form some transistorof the microcircuit under the bottom electrode of the MEMS and coupledthereto by one or more contacts, reducing the surface area dedicated tothe microcircuits. Use of high temperature capable contacts also enablesintegrated devices having microcircuits with three or more levels ofmetallization, while reducing material deposited over the MEMS thatneeds to be removed in a subsequent MEMS open etch step, all whileavoiding problems associated with high-aspect ratio contacts.

A cross-sectional side view of a portion of an integrated device 400with MEMS 402 and a microcircuit 404 including a three-levelmetallization scheme and a high-temperature contact is shown in FIG. 4.As with the microcircuit of the integrated device described above withrespect to FIG. 3, the microcircuit 404 of the integrated includes aplurality of transistors 408 separated by isolation structures 410 andincluding doped source-drain regions 412 and gates 414 formed in thesubstrate 406 adjacent to and/or underlying the MEMS 402. Contacts 416extend through openings etched in a dielectric layer 418 covering thetransistors 408 to electrically couple gates 414 of the transistors andother regions in the substrate 406 to a local interconnect (LI 420) forthe wiring of the microcircuit 404. Additional alternating metal anddielectric layers are formed over the LI 420 including a first patternedmetal layer (M1 422) overlying a first ILD 424 and a second patternedmetal layer (M2 426) overlying a second ILD 428.

The MEMS 402 includes at least one moveable actuator 430, a portion ofwhich is suspended above and separated from the substrate 406 by a gap432. The actuator 430 includes a layer of elastic material, such assilicon nitride layer 434, covered or overlaid by a film or layer ofmetal 436 that serves as both an actuator electrode and a reflectivesurface for the SLM. The actuator 430 is electrostatically deflected ormoved towards a bottom electrode 438 by application of a voltagedifferential applied between the electrode and the layer of metal 436.

The integrated device 400 of FIG. 4 and the fabrication thereof differsin a number of significant ways from that described above with respectto FIG. 3, including: (i) a high temperature capable metal contact 416,which includes a robust barrier layer 440; (ii) a thin protective bufferoxide 442 overlying the contact and LI 420; (iii) dry etching orpatterning of metal lines M1 422 and M2 426 in dense microcircuit 404area; and (iv) use of a highly selective wet removal of metal over MEMS402 structures. Finally, the microcircuit 404 can be encapsulated in oneor more layers of a cap-oxide or nitride 444.

A method or process flow for fabricating a high-temperature contactaccording to an embodiment of the present invention will now bedescribed in detail with reference to FIGS. 5A to 5H. Referring to FIG.5A, the method of forming a high-temperature contact 500 begins withdepositing or forming a dielectric layer 502 over a surface 504 of asubstrate 506. The substrate 506 may include any known semiconductormaterial, such as Silicon, Gallium-arsenide, Germanium, Gallium-nitride,Aluminum-phosphide, and mixtures or alloys thereof. Preferably, thesubstrate 506 is a doped or undoped silicon-based semiconductorsubstrate, such as a monocrystalline silicon, silicon-germanium,silicon-on-insulator, or silicon-on-sapphire substrate. The dielectriclayer 502 can include, for example, a doped or undoped oxide, such assilicon-dioxide (SiO₂), a nitride, such as silicon nitride(Si_(x)N_(y)), a silicon-oxynitride (Si_(x)O_(y)N_(z)) or a glass, suchas phosphosilicate glass (PSG) or borophosphosilicate glass (BPSG).Depending on the dielectric, the dielectric layer 502 can be formed orgrown, for example by thermal oxidation, or deposited by chemical vapordeposition (CVD) or plasma enhanced CVD (PECVD). Next, a contact opening508 is formed through the dielectric layer 502 to expose an underlyingstructure 509 of a microcircuit (not shown) at least partially formed inor on the substrate 506. The underlying structure 509 can include, forexample, a local interconnect (LI), a gate electrode of a semiconductordevice, or a diffusion region, such as source or drain regions of thedevice, formed prior to depositing or forming of the dielectric layer502. The LI or gate electrode layer can include any suitable conductingmetal or material including, for example, a dopedpolycrystalline-silicon (poly) layer or titanium nitride (TiN). Thecontact opening 508 is formed through the dielectric layer 502 usingstandard photolithographic and wet or dry etching techniques.Optionally, the method further includes cleaning the contact opening 508using an RF sputter etch-clean prior to further processing.

Referring to FIG. 5B, a thin seed layer 510 comprising a refractorymetal is deposited over the dielectric layer 502 and on at least onesurface 512, i.e., sidewalls and bottom, of the contact opening 508. Byrefractory metals it is meant metals of elements of the groups 4, 5 and6 of the periodic table, including titanium (Ti), tantalum (Ta),tungsten (W), and nitrides or alloys thereof, which are resistant tohigh temperatures. By thin it is meant a seed layer 510 having athickness of from 100 to 1000 Å deposited, for example, by physicalvapor deposition, such as sputtering or evaporation, or by electrolessplating. Optionally, as shown in FIG. 5C, the seed layer 510 can be amulti-layer seed layer including two or more layers each having athickness of between 100 to 1000 Å, and each having a differentstoichiometric composition of metals, nitrides or alloys. In oneembodiment, the multi-layer seed layer 510 can include a first or bottomlayer 510 a of titanium and a second or top layer 510 b oftitanium-tungsten (TiW).

Referring to FIG. 5D, next a top surface of the seed layer 510 isnitrided to form a barrier layer 514 to substantially preventinteraction of the subsequently deposited metal of the contact (notshown in this figure) with silicon in the underlying structure 509 of amicrocircuit. The barrier layer can include metal nitrides, such astitanium nitride (TiN), tantalum nitride (TaN), or a titanium-tungstennitride (TiWN_(X)), extending to a depth of from 10 to 100 Å top surfaceof the seed layer 510. In one embodiment, the barrier layer 514 is a TiNlayer that also serves as an adhesion layer to improve adhesion of themetal of the contact (not shown in this figure) to the underlyingstructure 509.

Nitriding of the seed layer 510 is accomplished by heating the substrate506 to a predetermined temperature and exposing the surface of the seedlayer 510 to a nitrogen containing atmosphere for a predetermined periodof time. In one embodiment, the substrate 506 is heated to a temperatureof between 750 to 950° C. in a process chamber of a rapid thermalprocessing (RTP) tool into which ammonia (NH₃) is introduced at a flowrate of between 10 to 10,000 standard cubic centimeters per minute(sccm) for between 10 to 500 seconds. When the ammonia comes intocontact with the heated substrate 506 it disassociates into hydrogen andnitrogen, which then diffuses into the surface of the seed layer 510. Inaddition, to nitriding the surface of the seed layer 510, heating thesubstrate 506 to a temperature of between 750 to 950° C. sinters theseed layer improving a final contact resistance of the contact 500.

Referring to FIG. 5E, a metal 516 is deposited over the barrier layer514 to form the contact 500 in the contact opening. Preferably, themetal 516 is a refractory metal resistant to high temperatures, such astitanium (Ti), tantalum (Ta), tungsten (W) or alloys thereof, and isdeposited by CVD or PECVD. In one embodiment, the metal 516 is tungsten(W) deposited by CVD over a titanium (Ti) seed layer 510, and atitanium-nitride (TiN) barrier layer 514.

Referring to FIG. 5F, the surface of the metal 516 is then planarized orpolished using a chemical mechanical planarization or polishing (CMP)process to provide a planar surface 518, over which a high temperaturecap (not shown in this figure) can be subsequently formed.

Referring to FIGS. 5G and 5H, the high temperature cap can include alocal interconnect 520 (LI) covered by a capping dielectric or oxide522. As with the underlying structure 509 the local interconnect 520include any suitably conducting material, such as TiN or dopedpolysilicon deposited, for example, by CVD and patterned using standardphotolithographic and wet or dry etching techniques. The oxide can begrown or deposited, for example, using CVD with atetraethylorthosilicate (TEOS) precursor.

Methods of fabricating an integrated device including a high-temperaturecontact of a microcircuit adjacent to a MEMS according to an embodimentof the present invention will now be described with reference to theflowchart of FIGS. 6A and 6B.

Referring to FIG. 6A, the method begins with the front-end offabrication of a plurality of transistors in the substrate (block 602).Generally, the plurality of transistors include one or more p-type or ann-type transistor metal oxide silicon (MOS) transistors, such as thosedescribed above in relation to FIGS. 3 and 4. The transistors can befabricated using conventional semiconductor fabrication processes. TheMOS transistor configuration illustrated in FIGS. 3 and 4 is forillustrative purposes only, and is alternative conventional transistorconfigurations can be used in addition to or in place of the MOStransistors.

Next, a dielectric layer is formed or deposited over the transistors anda surface of the substrate (block 604). The dielectric layer isdeposited over substantially the entire surface of the substrateincluding areas or region in which the MEMS will be formed. As notedabove, the dielectric layer can include a doped or undoped oxide, suchas silicon-dioxide (SiO₂), a nitride, such as silicon nitride(Si_(x)N_(y)), a silicon-oxynitride (Si_(x)O_(y)N_(z)) or a glass, suchas phosphosilicate glass (PSG) or borophosphosilicate glass (BPSG).Optionally or preferably, the dielectric layer is then planarized by aCMP process to provide a planar surface for the subsequent contactformation steps and to reduce the thickness of the dielectric layer.

A contact opening is then etched through the dielectric layer and a hightemperature capable contact formed therein using a process such as thatdescribed above with reference to FIGS. 5A through 5E (block 606). Thecontact and the dielectric layer are then planarized by a CMP process,and a TiN or doped polysilicon layer deposited and patterned to form theLI of the microcircuit and the bottom electrode of the MEMS 402 (block608). The LI is capped with an insulating layer, such as a buffer oxide(block 610). The insulating layer together with the LI forms a hightemperature cap over the tungsten plug of the contact, enabling it towithstand the high temperature processes of MEMS fabrication.

A sacrificial layer is deposited and patterned in the area or region inwhich the MEMS will be formed (block 612). The sacrificial layer caninclude, for example, silicon, and can be deposited using CVD or PECVD,and patterned using conventional photolithographic and wet or dry etchprocesses. Next, an elastic layer, such as a silicon nitride, isdeposited and patterned to form the actuators of the MEMS (block 614).The silicon nitride elastic layer can be deposited using CVD or PECVD,and patterned using conventional photolithographic and wet or dry etchprocesses.

The next step is the deposition of a first ILD layer over themicrocircuit and MEMS (block 616). As with the dielectric layerdescribed above, the first ILD layer can include a doped or undopedoxide, such as silicon-dioxide (SiO₂), a nitride, such as siliconnitride (Si_(x)N_(y)), a silicon-oxynitride (Si_(x)O_(y)N_(z)) or aglass, such as phosphosilicate glass (PSG) or borophosphosilicate glass(BPSG). Preferably, the first ILD layer is an undoped SiO₂ layer. Morepreferably, the first ILD layer is then planarized by a CMP process toprovide a planar surface for the subsequent steps and to reduce thethickness of the first ILD layer. As a result of the deposition andplanarization of the first ILD layer, the MEMS is embedded in aprotective layer so that a subsequent etching steps can be performedwithout damaging the silicon nitride layer.

An opening is then etched through the first ILD layer, and a layer ofmetal deposited and patterned to form a first metal layer (M1) of aninterconnect to the transistors (block 618). Preferably, the metal isdeposited by sputtering. Suitable metals include aluminum, titanium,tungsten, copper and alloys thereof. The patterning and etching of themetal layer is performed using conventional photolithographic and dryetching techniques. More preferably, the metal layer is overetched toensure that all of the metal not needed in forming the interconnect isremoved from the surface of the first ILD and over the MEMS. The firstILD acts as a buffer to allow for overetching of the metal layer withoutdamaging the silicon nitride layer of the underlying MEMS. Thus, thefirst ILD should have a minimum thickness of about 2000 Å.

Next, a second ILD layer is deposited over the patterned first metallayer (block 620). As with the first ILD layer, the second ILD layer caninclude a doped or undoped oxide, such as SiO₂, a nitride, such assilicon nitride, a silicon-oxynitride or a glass, such as PSG or BPSG.Preferably, the second ILD layer is an undoped SiO₂ layer. An opening isthen etched through the second ILD and a second layer of metal depositedand patterned to form a second metal layer (M2) (block 622). As with thefirst metal layer (M1), the second metal layer (M2) is overetched toensure that all of the metal not needed in forming the interconnect isremoved from the surface of the second ILD and over the MEMS.

Once the second layer of metal deposited and patterned to form a secondmetal layer (M2) all material above the MEMS is removed using a highlyselective wet etch (block 624). This is accomplished by applying openarray mask to protect the microcircuit interconnects while removing thefirst and second ILD material above the MEMS using a highly selective10:1 buffered oxide etch (BOE) wet etch. Alternatively, the wet etch canbe performed using a 20:1 BOE wet etch, a 50:1 hydrofluoric (HF) wetetch, a pad etch, or any other similar hydrofluoric-based wet oxideetching chemistry.

Next, a layer of a metal is deposited on the exposed silicon nitride ofthe actuators to form a reflective surface and actuator electrodes(block 626). Preferably, the metal layer is a thin layer formed usinglow-temperature processing steps, which are compatible with thelow-temperature processing such as sputtering. More preferably, thereflective metal layer is aluminum.

Openings are then etched through selected areas of the metal layer andthe silicon nitride through which an etchant, such as xenon difluoride(XeF₂), is introduced to etch or remove the sacrificial layer, releasingthe actuator (block 628). The openings can include rib cuts patterned inthe metal layer and the silicon nitride to form ribbons of a GLV™ typespatial light modulator.

Finally, the microcircuit can be encapsulated in one or more layers of acap-oxide or nitride 444 (block 630) to electrically insulate andprotect the microcircuit during backend processing and packaging.

In the preceding description, for purposes of explanation, numerousspecific details have been set forth in order to provide a thoroughunderstanding of the fabrication method of the present disclosure. Itwill be evident; however, to one skilled in the art that the presentmethod may be practiced to form integrated devices including MEMSdevices, microcircuits and/or ICs without these specific details. Inother instances, well-known structures, and techniques are not shown indetail or are shown in block diagram form in order to avoidunnecessarily obscuring an understanding of this description.

Reference in the description to “one embodiment” or “an embodiment”means that a particular feature, structure, or characteristic describedin connection with the embodiment is included in at least one embodimentof the integrated device. The appearances of the phrase “one embodiment”in various places in the specification do not necessarily all refer tothe same embodiment. The term “to couple” as used herein may includeboth to directly connect and to indirectly connect through one or moreintervening components.

The foregoing description of specific embodiments and examples have beenpresented for the purpose of illustration and description, and althoughdescribed and illustrated by certain of the preceding examples, theintegrated device, MEMS, microcircuits and ICs disclosed herein are notto be construed as being limited thereby. They are not intended to beexhaustive or to limit the method to the precise forms disclosed, andmany modifications, improvements and variations within the scope of thedisclosure are possible in light of the above teaching.

1. A method of fabricating an integrated device comprising: forming acontact through a dielectric layer to an underlying element of amicrocircuit formed adjacent to a MicroElectroMechanical System (MEMS)structure on a substrate; and depositing a layer of conducting materialover the dielectric layer, and patterning the layer of conductingmaterial to form a local interconnect (LI) for the microcircuitoverlying and electrically coupled to the contact and a bottom electrodefor the adjacent MEMS structure.
 2. The method of claim 1, whereinfurther comprising depositing and patterning a sacrificial layer overthe bottom electrode of the MEMS structure, and depositing a siliconnitride elastic layer over the patterned sacrificial layer to form anactuator of the MEMS using high temperature processing steps.
 3. Themethod of claim 2, wherein forming the contact comprises forming a hightemperature contact comprising a barrier layer formed on surfaces of anopening etched in the dielectric layer, and a metal plug deposited inthe opening over the barrier layer.
 4. A method according to claim 3,further comprising forming a thin protective buffer oxide over the LI ofthe microcircuit, and wherein the buffer oxide and LI form as atemperature resistant cap over the contact.
 5. The method of claim 3,further comprising: depositing a first interlevel dielectric (ILD) overthe LI and the MEMS structure; etching an opening through the first ILDto the LI, depositing and patterning a layer of metal to form a firstmetal interconnect (M1) layer for the microcircuit overlying andelectrically coupled to the LI; and wherein the layer of metal ispatterned by overetching using a dry etch process and the first ILDprotects the silicon nitride of the MEMS structure.
 6. The method ofclaim 5, further comprising: depositing a second ILD over the first M1layer and the MEMS structure; etching an opening through the second ILDto the M1 layer, depositing and patterning a layer of metal to form asecond metal interconnect (M2) layer for the microcircuit overlying andelectrically coupled to the M1 layer using a dry etch process.
 7. Themethod of claim 6, further comprising forming a mask over themicrocircuit and removing the first and second ILD overlying the MEMSstructure using a selective wet etch process.
 8. A method of fabricatingan integrated device comprising: forming a contact opening through adielectric layer to an underlying structure of a microcircuit on asubstrate; depositing a seed layer comprising a refractory metal on asurface of the contact opening; nitriding the seed layer to form abarrier layer on a surface thereof; depositing a metal over the barrierlayer to form a contact in the opening; forming a temperature resistantcap over the contact; and fabricating at least a portion of aMicroElectroMechanical System (MEMS) on the substrate adjacent to thecontact.
 9. A method according to claim 8, wherein nitriding the seedlayer comprises heating the substrate in a nitrogen containingatmosphere.
 10. A method according to claim 9, wherein heating thesubstrate comprises heating the substrate to a temperature of between750 to 950° C. to sinter the seed layer.
 11. A method according to claim10, wherein heating the substrate in a nitrogen containing atmospherecomprises introducing ammonia (NH₃) into a process chamber of a processtool at a flow rate of between 10 to 10,000 standard cubic centimetersper minute (sccm).
 12. A method according to claim 10, wherein heatingthe substrate comprises heating the substrate in a rapid thermalprocessing (RTP) tool for between 10 to 500 seconds.
 13. A methodaccording to claim 8, further comprising cleaning the contact openingusing an RF sputter etch-clean prior to depositing the seed layer.
 14. Amethod according to claim 8, wherein depositing the seed layer comprisesdepositing from 100 to 1000 Å of titanium (Ti).
 15. A method accordingto claim 14, wherein depositing the seed layer further comprisesdepositing from 100 to 1000 Å of titanium-tungsten (TiW).
 16. A methodaccording to claim 8, wherein depositing a metal over the barrier layerto form the contact in the opening comprises depositing tungsten (W).17. A method according to claim 16, further comprising planarizing thetungsten using chemical mechanical planarization (CMP) prior to formingthe temperature resistant cap over the contact.
 18. A method accordingto claim 8, wherein forming the temperature resistant cap over thecontact comprises forming a polysilicon local interconnect (LI) coveredby an oxide over the contact.
 19. An integrated device comprising adiffractive light modulator adjacent to a microcircuit on a singlesubstrate, the microcircuit including a plurality of transistors formedin the substrate, a local interconnect (LI) layer and at least two metalinterconnect layers through which the plurality of transistors areelectrically coupled to the diffractive light modulator.
 20. Anintegrated device according to claim 19, wherein the microcircuitfurther comprises a high temperature contact through a dielectric layerto electrically couple the LI layer to at least one of the underlyingplurality of transistors, and wherein the contact comprises a barrierlayer, a metal deposited over the barrier layer and a temperatureresistant cap.